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US 20180137967A1
(19 ) United States
( 12 ) Patent Application Publication (10 ) Pub. No.: US 2018 /0137967 A1
Honna et al. (43) Pub. Date : May 17 , 2018
(54 ) HIGH FREQUENCY TRANSFORMER (52) CPC
U .S . CI...... HOIF 27 /2828 ( 2013 .01); HOIF 27/2847
(71) Applicant: Seiden Mfg. Co., Ltd., Kanagawa (JP) (2013 .01 ); HOIF 27/ 28 (2013 .01) ; HOIF
27 /255 ( 2013 .01); HOIF 19 /04 (2013 .01 )
(72 ) Inventors : Tsunehiko Honna , Kanagawa (JP );
Minoru Ishikawa, Kanagawa (JP ) (57 ) ABSTRACT
(21 ) Appl. No.: 15 /869 ,698 A high frequency transformer with high conversion effi
ciency is provided . The high frequency transformer includes
(22) Filed : Jan . 12 , 2018 a first coil assembly 1 formed from a single flat wire , with
first coils 1A that are configured by winding the flat wire
Related U .S . Application Data edgewise plural times and that are formed at specific inter
vals, and a second coil assembly 2 formed from a single flat
(62 ) Division of application No . 14 / 124 ,046 , filed on Dec . wire , with second coils 2A that are configured by winding
5 , 2013 , now Pat . No. 9 , 881 ,728 , filed as application the flat wire edgewise plural times and that are formed at
No. PCT/JP2012 /062549 on May 16 , 2012 . specific intervals . In the primary coil assembly 1 and the
secondary coil assembly 2 , the primary coils 1A are disposed
( 30 ) Foreign Application Priority Data at intervals to each other such that a winding end portion of
one of adjacent primary coils 1A opposes a winding start
Jun. 10, 2011 (JP ) ............ ................ 2011 - 130429 portion of the other of the adjacent primary coils 1A , and one
Publication Classification of the secondary coils 2A is disposed in each interval
between the primary coils 1A such that a winding start
(51) Int. CI. portion of each secondary coil 2 opposes the winding end
HOIF 27/28 ( 2006 .01) portion of one of the primary coils 1A , and a winding end
HOIF 19 /04 (2006 .01) portion of each secondary coil 2A opposes the winding start
HOIF 27/ 255 ( 2006 .01) portion of the other of the primary coils .

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Patent Application Publication May 17, 2018 Sheet 53 of 53 US 2018/0137967 A1

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US 2018/0137967 A1 May 17, 2018

HIGH FREQUENCY TRANSFORMER [0009] In the above transformers, increasing the thickness
and width of flat wires configuring the primary coil and the
RELATED APPLICATION DATA secondary coil such that a larger current flows may be
[ 0001] This application is a divisional application which considered . However there is an issue with flat wire of large
claims priority to U . S . patent application Ser. No . 14 / 124 , cross - sectional area in that alternating current resistance
046 , filed on Dec . 5 , 2013 , which is a National Stage increases due to the skin effect when a high frequency
Application under 35 U . S . C . 371 of co -pending PCT appli current flows in the primary coil and the secondary coil, and
cation PCT/ JP2012 /062549 designating the United States a uniform current does not readily flow inside the conductor.
and filed May 16 , 2012 ; which claims the benefit of JP [0010 ] In the above transformers, leakage inductance also
increases at both end portions of the primary coil and the
application number 2011-130429 and filed Jun . 10 , 2011 secondary coil due to alternately mounting the primary coil
each of which are hereby incorporated by reference in their windings and the secondary coil windings into the core . The
entireties . degree of coupling between the primary coil and the sec
ondary coil is accordingly much lower than 1 . The energy
TECHNICAL FIELD transfer efficiency from the primary side to the secondary
[0002] The present invention relates to a high frequency side is accordingly well below 100 % , with the issue that a
transformer, in particular relates to a high frequency trans large amount of loss occurs during energy transfer from the
former with high conversion efficiency . primary coil to the secondary coil.
[0011 ] In consideration of the above circumstances, an
BACKGROUND ART object of the present invention is to provide a high frequency
transformer with extremely small leakage inductance, and a
100031 Transformers exist in which gaps that are substan coupling rate that is very close to 1 , such that loss during
tially equal in width to a flattened rectangular conductor are energy transfer from the primary coil to the secondary coil
provided between layers of two edgewise coils 1a , 1b . The is extremely small.
flattened rectangular conductor layers of the edgewise coils
1a, 1b are individually assembled into the gaps so as to be Solution to Problem
alternately mounted to the core, thereby reducing leakage
inductance and enhancing coupling properties. In such trans [0012 ] A high frequency transformer of a first aspect of the
formers , insulation reinforcement is performed on the flat present invention includes: a first coil assembly formed from
wires (Patent Document 1) . a single flat wire , with plural first coils that are respectively
[0004 ] Transformers also exist that are formed by attach configured by winding the flat wire edgewise plural times
ing, to four corners on a core 1 contact side of a core 1 , a and are formed at specific intervals such that a winding end
spacer 2 that is provided with notches so as to conform to the portion of one first coil out of adjacent first coils opposes a
corners of the core 1. Flat wires of a primary winding 3 and winding start portion of the other first coil out of the adjacent
a secondary winding 4 wound in coil shapes are interposed first coils ; and a second coil assembly formed from a single
such that one cross -section length direction end thereof is flat wire , with plural second coils that are respectively
inserted into a comb shaped recess portion provided to a side configured by winding the flat wire edgewise plural times
face of the spacer 2 that retains the winding. and are formed at specific intervals such that a winding end
[0005 ] In the transformer described above, the primary portion of one second coil out of adjacent second coils
winding 3 and the secondary winding 4 are retained at a opposes a winding start portion of the other second coil out
specific separation by projection portions of the spacer 2 . of the adjacent second coils ; with the first coil assembly and
Moreover , the windings are insulated from and retained at a the second coil assembly disposed such that the second coils
separation to the core 1 by a main body portion of the spacer are inserted between adjacent first coils such that a winding
2 . An increase in temperature of the transformer can more start portion of each of the second coils in the second coil
over be suppressed by flowing cooling air between the assembly opposes a winding end portion of one of adjacent
windings themselves and between the windings and the core first coils in the first coil assembly, and a winding end
portion of each of the second coils opposes a winding start
10006 ] Patent Document 1: Japanese Patent Application portion of the other of the adjacent first coils.
Laid - Open (JP - A ) No. 2004 - 103624 [0013] In the high frequency transformer of the first
aspect, the first coil assembly and the second coil assembly
[0007] Patent Document 2: JP -A No. 2006 - 147927 are respectively formed from a single flat wire . There is
accordingly no need for a connection operation such as
SUMMARY OF INVENTION soldering to connect together respective first coils and
Technical Problem second coils , unlike in a high frequency transformer in
which plural first coils and second coils are respectively
[0008 ] However, in the transformers described in Patent connected together to configure the first coil assembly and
Document 1 and Patent Document 2 , both the edgewise coils the second coil assembly . Manufacturing the transformer is
1a, 1b are configured from a flat wire of the same width and accordingly easy , with good environmental characteristics
thickness . Application is accordingly difficult in situations due to being a lead -free configuration .
such as when a high voltage alternating current is input to [0014 ] A high frequency transformer of a second aspect of
the primary coil and a large alternating current is desired to the present invention includes: a first coil assembly includ
be output from the secondary coil , or when a large alternat- ing plural first coils that are respectively configured by
ing current is input to the primary coil and a high voltage winding a flat wire edgewise plural times, with the first coils
alternating current is desired to be output from the secondary disposed at specific intervals such that a winding end portion
coil. of one first coil out of adjacent first coils opposes a winding
US 2018/0137967 A1 May 17, 2018

start portion of the other first coil out of the adjacent first [0020 ] Moreover, since at least the secondary coil assem
coils ; and a second coil assembly including plural second bly is formed from a single continuous flat wire , there is no
coils that are respectively configured by winding a flat wire need for a connection operation such as soldering to connect
edgewise plural times, with the second coils disposed at together the secondary coils. Manufacturing is accordingly
specific intervals such that a winding end portion of one made easier than for a high frequency transformer in which
second coil out of adjacent second coils opposes a winding the primary coil assembly and the secondary coil assembly
start portion of the other second coil out of the adjacent are both configured by connecting together plural primary
second coils ; wherein one coil assembly out of the first coil coils and secondary coils .
assembly or the second coil assembly is formed from a [0021] A fifth aspect of the present invention is a high
single flat wire , the other coil assembly out of the first coil frequency transformer including: plural primary coils
assembly and the second coil assembly is formed by con formed by winding a flat wire edgewise plural times, and
necting together in series or in parallel plural coils that are plural secondary coils formed by winding a flat wire edge
respectively configured by winding a flat wire edgewise wise plural times, wherein the secondary coils are disposed
plural times , with the first coil assembly and the second coil at intervals such that a winding end portion of one of the
assembly disposed such that the second coils are inserted secondary coils and a winding start portion of another of the
between adjacent of the first coils such that a winding start secondary coils that is adjacent to the one secondary coil
portion of each of the second coils in the second coil oppose each other, and one individualof the primary coils is
assembly opposes a winding end portion of one of adjacent disposed inside each of the respective intervals such that a
first coils in the first coil assembly , and a winding end winding start portion of each of the primary coils opposes a
portion of each of the second coils opposes a winding start winding end portion of the one secondary coil, and a
portion of the other of the adjacent first coils . winding end portion of the primary coil opposes a winding
[0015 ] The high frequency transformer of the second start portion of the other secondary coil, and a primary coil
aspect can accommodate various voltages and currents by assembly is configured by connecting the primary coils in
selecting from series connection or parallel connection for series or in parallel at the outside of the secondary coils so
the connection of the coils of the coil assemblies that are as to connect across the secondary coils , and a secondary
formed by connecting together plural coils for the first coil coil assembly is configured by connecting the secondary
assembly and the second coil assembly . coils in series or in parallel at the outside of the primary coils
[0016 ] A third aspect of the present invention is the high so as to connect across the primary coils .
frequency transformer of either the first or the second aspect, [0022 ] The high frequency transformer of the fifth aspect
wherein : the first coils are primary coils and the second coils is configured such that the primary coils are inserted
are secondary coils , and the first coil assembly is a primary between two adjacent secondary coils, such that it is easy to
coil assembly and the second coil assembly is a secondary configure a higher number of turns of the flat wire in the
coil assembly overall secondary coil assembly than in the primary coil
[0017] In the high frequency transformer of the third assembly . The high frequency transformer is accordingly
aspect, both the primary coils and the secondary coils are appropriately employed in applications wherein a high volt
formed by winding a flat wire edgewise plural times. The age high frequency current is output.
primary coils and the secondary coils are disposed alter [0023] A sixth aspect of the present invention is the high
nately to one another, with configuration made such that the frequency transformer of the third aspect, wherein the num
secondary coils are disposed between two adjacent primary ber of the primary coils is 4 or more , and the number of the
coils. Leakage inductance can accordingly be made secondary coils is 3 or more .
extremely small since a uniform magnetic field generated by [0024 ] The high frequency transformer of the sixth aspect
the primary coils passes through the secondary coils when a exhibits excellent conversion efficiency in comparison to a
high frequency current flows in the primary coils. The high frequency transformer in which there are 2 or 3 of the
degree of coupling between the primary coils and the primary coils and 1 or 2 of the secondary coils.
secondary coils is accordingly very close to 1, enabling an [0025 ] A seventh aspect of the present invention is the
energy transfer rate from the primary coils to the secondary high frequency transformer of the fourth of the fifth aspect,
coils of almost 100 % , and enabling loss during energy wherein the number of the secondary coils is 4 or more , and
transfer from the primary coils to the secondary coils to be the number of the primary coils is 3 or more .
suppressed to an extremely small amount. [0026 ] The high frequency transformer of the seventh
[0018] A fourth aspect of the present invention is the high aspect exhibits excellent conversion efficiency in compari
frequency transformer of either the first or the second aspect , son to a high frequency transformer in which there are 1 or
wherein : the first coils are secondary coils and the second 2 of the primary coils and 2 or 3 of the secondary coils .
coils are primary coils, and the first coil assembly is a 10027] An eighth aspect of the present invention is the
secondary coil assembly and the second coil assembly is a high frequency transformer of any one of the second to the
primary coil assembly . seventh aspects, wherein an insulating member is inserted
[0019] The high frequency transformer of the fourth between the primary coils and the secondary coils .
aspect is configured such that the primary coils are inserted [0028 ] In the high frequency transformer of the eighth
between two adjacent secondary coils, such that it is easy to aspect, the insulating member is inserted between the pri
configure a higher number of turns of the flat wire in the mary coils and the secondary coils , thereby maintaining an
overall secondary coil assembly than in the primary coil insulation distance between the primary coils and the sec
assembly . The high frequency transformer is accordingly ondary coils more uniformly in comparison to in a high
appropriately employed in applications wherein a high fre frequency transformer in which the insulating member is not
quency current of a high voltage is output. inserted between the primary coils and the secondary coils ,
US 2018/0137967 A1 May 17, 2018

thereby obtaining more reliable insulation between the pri- pair of central cores of the core - type core and secondary coil
mary coils and the secondary coils. assemblies that are respectively mounted on the pair of
[0029] A ninth aspect of the present invention is the high central cores are respectively connected in series .
frequency transformer of any one of the second to the eighth [0038 ] The high frequency transformer of the thirteenth
aspects , wherein the flat wire configuring the primary coil aspect may be suitably employed in applications in which
assembly and the flat wire configuring the secondary coil both input and output are high voltage high frequency
assembly differ from each other in width , in thickness, or in currents .
both width and thickness. [0039 ] A fourteenth aspect of the present invention is the
[0030 ] In the high frequency transformer of the ninth high frequency transformer of the twelfth aspect, wherein at
aspect , the flat wire configuring the primary coils and the flat least one of primary coil assemblies respectively mounted
wire configuring the secondary coils differ from each other on a pair of central cores of the core - type core or secondary
in width , in thickness , or in both width and thickness . The coil assemblies respectively mounted on the pair of central
width and thickness of the flat wires can accordingly be set cores are connected in parallel.
to match the currents that are to flow in the primary coils and [0040 The high frequency transformer of the fourteenth
the secondary coils , such that when the current that is to flow aspect 14 may be suitably employed in applications in which
in the secondary coils is greater than the current of the at least one of the input and the output is a high frequency
primary coils the width , the thickness or both the width and current with a low voltage and a large current.
the thickness of the flat wire of the secondary coils are set [0041 ] A fifteenth aspect of the present invention is the
greater than that of the flat wire of the primary coils, and high frequency transformer of any one of the second to the
when the current that will flow in the primary coils is greater ninth aspects , further comprising : the primary coil assem
than the current of the secondary coils , the width or the blies and the secondary coil assemblies provided by three ;
thickness or both the width and the thickness of the flat wire three columnar cores that are formed from ferrite and are
of the primary coils is set greater than the flat wire of the disposed at even intervals around the circumference of a
secondary coils . A high frequency transformer can accord circle ; a top plate that is formed from ferrite and is coupled
ingly be configured that is adapted for various input and to one end of each of the columnar cores; and a bottom plate
output conditions. that is formed from ferrite and is coupled to the other end of
[ 0031] A tenth aspect of the present invention is the high each of the columnar cores ; wherein the three columnar
frequency transformer of any one of the second to the ninth cores are respectively inserted into each of the primary coil
aspects , wherein a ferrite core is inserted through the pri assemblies and each of the secondary coil assemblies , and
mary coil assembly and the secondary coil assembly. the primary coil assemblies and the secondary coil assem
[ 0032 ] In the high frequency transformer of the tenth blies are respectively configured with a Y connection , or
aspect, loss during use at high frequencies is small due to with a delta connection .
employing a ferrite core as the core . [0042] The high frequency transformer of the fourteenth
[ 0033] An eleventh aspect of the present invention is the aspect is a three -phase high frequency transformer, and
high frequency transformer of the tenth aspect, wherein the therefore has three times the capacity of a single phase high
ferrite core is a shell-type core . frequency transformer for the same primary coils, secondary
[0034 ] In the high frequency transformer of the eleventh coils and leg portion cores for inserting the coils . The high
aspect, the ferrite core is a shell-type core . The ratio of the frequency transformer is accordingly suitably applied in
core to the coils is accordingly higher than in a high high capacity power converting equipment and high capac
frequency transformer in which the ferrite core is a core -type ity power source equipment. Moreover, the basic ripple
core , leading to stronger characteristics of an iron machine . percentage of the output of a secondary side rectification
The high frequency transformer is accordingly suitably circuit of a three - phase high frequency transformer is 4 .2 % ,
employed in applications with a small number of turns of the this being 1/10 or less than that of a single phase high
primary coils and the secondary coils, in particular in high frequency transformer for which an all -wavelength rectifi
frequency inverters (in the region of 50 kHz to 1 MHz). cation circuit has a basic ripple percentage reaching 48 % .
[0035 ] Atwelfth aspect of the present invention is thehigh Accordingly , it is sufficient to employ a filter with a small
frequency transformer of the tenth aspect, wherein the ferrite capacitance to reduce output ripple .
core is a core - type core . 10043 ] Since configuration may be made with such a filter
[0036 ] In the high frequency transformer of the twelfth with low capacitance , energy accumulation in the filter is
aspect , the ferrite core is a core -type core. The ratio of the also reduced . As a result, there is very little energy discharge
core to the coils is accordingly lower than in a high fre during output short circuiting, such that very little damage to
quency transformer in which the ferrite core is a shell - type the product is sustained due to arc discharge occurring
core , leading to stronger characteristics of a coppermachine . during sputtering when a high capacity DC sputtering power
A large number of turns can accordingly be secured for the source device is employed , thereby enabling product yield to
primary coils and the secondary coils , in particular giving a be improved .
margin in the density of magnetic flux passing through the 0044 ]. Moreover, the primary coil assemblies configured
inside of the core in cases in which the frequency is from the plural primary coils inserted onto the columnar
controlled , such as in a parallel resonant inverter or in a cores and the secondary coil assemblies configured from the
series resonant inverter, such that the high - frequency trans plural secondary coils inserted onto the columnar cores may
former is suitably applied when widening a control range as respectively be configured with either a Y connection or a
far as low frequencies (in the region of 10 kHz to 200 kHz). delta connection . The high frequency transformer moreover
[0037] A thirteenth aspect of the present invention is the includes cases in which the primary coil assemblies are
high frequency transformer of the twelfth aspect, wherein configured with a Y connection and the secondary coil
primary coil assemblies that are respectively mounted on a assemblies are configured with a Y connection , cases in
US 2018/0137967 A1 May 17, 2018

which the primary coil assemblies are configured with a having insulation washers that are inserted between primary
delta connection and the secondary coil assemblies are coils and secondary coils instead of an insulating member,
configured with a Y connection , cases in which the primary FIG . 12B is a side view of this example , and FIG . 12C is a
coil assemblies are configured with a Y connection and the rear view of this example .
secondary coil assemblies are configured with a delta con [0058 ] FIG . 13 is a wiring diagram illustrating wiring of
nection , and cases in which both the primary coil assemblies primary coils and secondary coils of the high frequency
and the secondary coil assemblies are configured with a transformer of the second exemplary embodiment.
delta connection . [00591. FIG . 14 is a plan view of a three phase high
frequency transformer of a third exemplary embodiment.
Advantageous Effects of Invention [0060 ] FIG . 15 is a side view illustrating a configuration of
the three - phase high frequency transformer of the third
[0045] As described above, the present invention provides exemplary embodiment as viewed along the direction of
a high frequency transformer with high conversion effi arrow A in FIG . 14 .
ciency that can prevent a drop in secondary output voltage [0061] FIG . 16 is a side view illustrating a configuration of
during load current flow , and can also prevent heat build - up the three phase high frequency transformer of the third
between primary coils and secondary coils since the voltage exemplary embodiment as viewed along the direction of
ratio of the secondary output voltage matches the turn ratio arrow B in FIG . 14 .
between the primary coils and the secondary coils .
[0062 ] FIG . 17 is a side view illustrating an example of the
BRIEF DESCRIPTION OF DRAWINGS three phase high frequency transformer of the third exem
plary embodiment having insulation washers that are
[0046 ] FIG . 1 is a plan view of a high frequency trans inserted between primary coils and secondary coils instead
former according to a first exemplary embodiment. of insulating members .
[ 0047 FIG . 2 is a front view illustrating a configuration of [0063] FIG . 18 is a wiring diagram illustrating wiring of
the high frequency transformer according to the first exem primary coils and secondary coils of the three phase high
plary embodiment as viewed along the direction of arrow A frequency transformer of the third exemplary embodiment .
in FIG . 1 . 10064 ] FIG . 19 is a plan view of a high frequency trans
[0048 ] FIG . 3 is a side view illustrating a configuration of former of a fourth exemplary embodiment.
the high frequency transformer according to the first exem 10065 ] FIG . 20 is a front view illustrating a configuration
plary embodiment as viewed along the direction of arrow B of the high frequency transformer of the fourth exemplary
in FIG . 1 . embodiment as viewed along the direction of arrow A in
[0049 ] FIG . 4 is a rear view illustrating a configuration of FIG . 19 .
the high frequency transformer according to the first exem [0066 ] FIG . 21 is a side view illustrating a configuration of
plary embodiment as viewed along the direction of arrow C the high frequency transformer of the fourth exemplary
in FIG . 1. embodiment as viewed along the direction of arrow B in
[0050 ] FIG . 5A is a plan view of the high frequency FIG . 19 .
transformer of the first exemplary embodiment taken along [0067] FIG . 22 is a rear view illustrating a configuration of
plane X - X in FIG . 3 , and FIG . 5B is a plan view of the high the high frequency transformer of the fourth exemplary
frequency transformer of the first exemplary embodiment embodiment as viewed along the direction of arrow C in
taken along plane Y - Y in FIG . 3 . FIG . 19 .
[0051] FIG . 6A is a front view of an example of the high [0068] FIG . 23A is a plan view of a high frequency
frequency transformer of the first exemplary embodiment transformer of the fourth exemplary embodiment taken
having insulation washers inserted between primary coils along plane X - X in FIG . 21 , and FIG . 23B is a plan view of
and secondary coils instead of an insulating member in , FIG . a high frequency transformer of the fourth exemplary
6B is a side view of this example , and FIG . 6C is a rear view embodiment taken along plane Y - Y in FIG . 21 .
of this example . [0069 ] FIG . 24 is a wiring diagram illustrating wiring of
[0052] FIG . 7 is a wiring diagram illustrating wiring of primary coils and secondary coils of the high frequency
primary coils and secondary coils of the high frequency transformer of the fourth exemplary embodiment.
transformer of the first exemplary embodiment. [0070] FIG . 25 is a plan view of a high frequency trans
[0053] FIG . 8 is a plan view of a high frequency trans former of a fifth exemplary embodiment.
former of a second exemplary embodiment. [0071 ] FIG . 26 is a front view illustrating a configuration
[0054 ] FIG . 9 is a front view illustrating the configuration of the high frequency transformer of the fifth exemplary
of the high frequency transformer of the second exemplary embodiment as viewed along the direction of arrow A in
embodiment as viewed along the direction of arrow A in FIG . 25 .
FIG . 8. 100721. FIG . 27 is a side view illustrating a configuration of
[0055 ] FIG . 10 is a side view illustrating the configuration the high frequency transformer of the fifth exemplary
of the high frequency transformer of the second exemplary embodiment as viewed along the direction of arrow B in
embodiment as viewed along the direction of arrow B in FIG . 25 .
FIG . 8 . [0073 ] FIG . 28 is a rear view illustrating a configuration of
[0056 ] FIG . 11 is a rear view illustrating the configuration the high frequency transformer of the fifth exemplary
of the high frequency transformer of the second exemplary embodiment as viewed along the direction of arrow C in
embodiment as viewed along the direction of arrow C in FIG . 25 .
FIG . 8 . [0074 ] FIG . 29 is a wiring diagram illustrating wiring of
[0057] FIG . 12A is a front view of an example of the high primary coils and secondary coils of a high frequency
frequency transformer of the second exemplary embodiment transformer of the fifth exemplary embodiment.
US 2018/0137967 A1 May 17, 2018

[0075 ] FIG . 30 is a plan view of a three phase high [0098 ] FIG . 53 is a plan view of a high frequency trans
frequency transformer of a sixth exemplary embodiment. former of a twelfth exemplary embodiment.
[ 0076 ] FIG . 31 is a side view illustrating a configuration of [0099] FIG . 54 is a front view of the high frequency
the three phase high frequency transformer of the sixth transformer of the twelfth exemplary embodiment .
exemplary embodiment as viewed along the direction of [0100 ] FIG . 55 is a side view of the high frequency
arrow A in FIG . 30. transformer of the twelfth exemplary embodiment.
[0077] FIG . 32 is a side view illustrating a configuration of [0101 ] FIG . 56 is a rear view of the high frequency
the three phase high frequency transformer of the sixth transformer of the twelfth exemplary embodiment .
exemplary embodiment as viewed along the direction of (0102 ] FIG . 57 is a wiring diagram illustrating connec
arrow B in FIG . 30 . tions of primary coils and secondary coils in the high
[0078 ] FIG . 33 is a side view illustrating an example of the frequency transformer of the twelfth exemplary embodi
three phase high frequency transformer of the sixth exem ment .
plary embodiment having insulation washers that are
inserted between primary coils and secondary coils instead DESCRIPTION OF EMBODIMENTS
of insulating members .
[0079 ] FIG . 34 is a wiring diagram illustrating wiring of 1. First Exemplary Embodiment
ent
primary coils and secondary coils of a three phase high [0103] Explanation follows regarding an example of an
frequency transformer of the sixth exemplary embodiment. exemplary embodiment of thehigh frequency transformer of
[0080 ] FIG . 35 includes a front view , a side view and a the present invention , in which a primary coil assembly and
rear view of a high frequency transformer of a seventh a secondary coil assembly are respectively formed from
exemplary embodiment. single flat wires, and in which secondary coils are inserted
10081] FIG . 36 is a plan view of the high frequency between primary coils .
transformer of the seventh exemplary embodiment. [0104 ] As illustrated in FIG . 1 to FIG . 6 , a high frequency
0082] FIG . 37 is a wiring diagram illustrating connec transformer 10 of the first exemplary embodiment is pro
tions of primary coils and secondary coils in the high vided with a core - type ferrite core 3 that includes two
frequency transformer of the seventh exemplary embodi circular cylinder shaped cores 3A and that is configured with
ment . an overall square frame shape. The high frequency trans
[0083] FIG . 38 includes a front view , a side view and a former 10 also includes a pair of primary coil assemblies 1
rear view of a high frequency transformer of the eighth and a pair of secondary coil assemblies 2 into which the
exemplary embodiment. respective cylinder shaped cores 3A is inserted .
[0084 ] FIG . 39 is a plan view of the high frequency [0105 ] As illustrated in FIG . 1 to FIG . 7 , the pair of
transformer of the eighth exemplary embodiment. primary coil assemblies 1 are arrayed in series, with the
[0085 ] FIG . 40 is a wiring diagram illustrating connection overall pair of primary coil assemblies 1 formed from a
of primary coils and secondary coils of the high frequency single continuous surface insulated flat wire . Each of the
transformer of the eighth exemplary embodiment. primary coil assemblies 1 is formed with four primary coils
(0086 ] FIG . 41 includes a front view , a side view and a 1A in uniform intervals , with each of the primary coils 1A
rear view of a high frequency transformer of a ninth exem configured by four turns of the flat wire wound edgewise .
plary embodiment. Note that winding edgewise refers to a winding method in
[0087] FIG . 42 is a plan view of the high frequency which the flat wire is wound along the width direction .
transformer of the ninth exemplary embodiment. [0106 ] The pair of secondary coil assemblies 2 is similarly
[0088 ] FIG . 43 is a wiring diagram illustrating connec arrayed in series , with the overall pair of secondary coil
tions of primary coils and secondary coils in the high assemblies 2 formed from a single continuous surface insu
frequency transformer of the ninth exemplary embodiment. lated flat wire . The respective secondary coil assemblies 2
[0089] FIG . 44 is a plan view of a high frequency trans are formed with three secondary coils 2A in uniform inter
former of a tenth exemplary embodiment. vals , respectively configured by three turns of the flat wire
[0090 ] FIG . 45 is a front view of the high frequency wound edgewise . Note that as illustrated in FIG . 1 to FIG .
transformer of the tenth exemplary embodiment . 5 , the secondary coils 2A employ flat wire that is greater in
[0091 ] FIG . 46 is a rear view of the high frequency both width and thickness than the flat wire of the primary
transformer of the tenth exemplary embodiment. coils 1A .
0092 FIG . 47 is a wiring diagram illustrating connec [0107 ] The primary coils 1A of the primary coil assem
tions of primary coils and secondary coils in the high blies 1 are formed such that a winding end portion of one of
frequency transformer of the tenth exemplary embodiment. mutually adjacent primary coils 1A opposes a winding start
[0093] FIG . 48 is a plan view of a high frequency trans portion of the other of the mutually adjacent primary coils
former of an eleventh exemplary embodiment. 1A . Similarly , the secondary coils 2A of the secondary coil
[ 0094 ] FIG . 49 is a front view of the high frequency assemblies 2 are formed such that a winding end portion of
transformer of the eleventh exemplary embodiment. one of mutually adjacent secondary coils 2A opposes a
[0095 ] FIG . 50 is a side view of the high frequency winding start portion of the other of the mutually adjacent
transformer of the eleventh exemplary embodiment. secondary coils 2A .
[ 0096 ] FIG . 51 is a rear view of the high frequency 10108 ] In the primary coil assemblies 1 and the secondary
transformer of the eleventh exemplary embodiment. coil assemblies 2 , the secondary coils 2A are disposed
00971 FIG . 52 is a wiring diagram illustrating connec inserted between adjacent primary coils 1A such that the
tions of primary coils and secondary coils in the high winding start portion of each of the secondary coils 2A of the
frequency transformer of the eleventh exemplary embodi secondary coil assemblies 2 opposes the winding end por
ment. tion of one of adjacent primary coils 1A of the primary coil
US 2018 /0137967 A1 May 17 , 2018

assemblies 1 , and the winding end portion of each of the coil assembly 2 similarly to at the winding start portion of
secondary coils 2A opposes the winding start portion of the the one secondary coil assembly 2 . The lead wire 2C outputs
other of the adjacent primary coils 1A . In other words, the a high frequency current with a current and voltage corre
primary coil assemblies 1 and the secondary coil assemblies sponding to the ratio of turns between the primary coils 1
2 are configured with the primary coils 1A and the secondary and the secondary coils .
coils 2A combined with each other such that the secondary [0113 ] As illustrated in FIG . 1 to FIG . 5 , insulating mem
coils 2A of the secondary coil assemblies 2 are inserted bers 7 are inserted between the respective primary coil
coaxially between the primary coils 1A of the primary coil assemblies 1 and the secondary coil assemblies 2 and the
assemblies 1 . cores 3A of the core -type ferrite core 3 . The insulating
[0109] Note that the number of turns of the primary coils members 7 are configured with insulation tabs 7A that
1A and the secondary coils 2A do not necessarily have to be extend towards the outside , and an insulation tab retaining
the number of turns illustrated in FIG . 1 to FIG . 6 , and may member 7B that retains the insulation tabs 7A at specific
be determined based on a ratio between the high frequency intervals. The insulation tabs 7A of the insulating members
current input into the primary coil assemblies 1 and the high 7 are inserted between the primary coils 1A and the sec
frequency current output from the secondary coils . For o ndary coils 2A , and the insulation tab retaining member 7B
example , in cases in which the high frequency transformer is inserted between the primary coils 1A and secondary coils
10 outputs large currents of high frequency, each of the 2A , and the cores 3A . Note that in the high frequency
primary coils 1A may be configured with seven turns, and transformer 10 the insulating members 7 may be inserted
each of the secondary coils 2A may be configured with two from the outside of the primary coils 1A and the secondary
turns, or the 2 primary coils 1A positioned at both end coils 2A . Moreover, as illustrated in FIG . 6 , insulation
portions of the respective primary coil assemblies 1 may be washers 8 that are ring shaped insulation plates or insulation
configured with six turns, and the two primary coils 1A sheets , may be inserted between the primary coils 1A and the
positioned at central portions of the primary coil assemblies secondary coils 2A instead of inserting the insulating mem
1 may be configured with eight turns, with each of the bers 7 .
secondary coils 2A configured with two turns. Note that in [0114 ] In the high frequency transformer 10 of the first
the drawings from FIG . 1 onwards, the primary coils 1A and exemplary embodiment, the primary coils 1A and the sec
the secondary coils 2A are respectively illustrated such that ondary coils 2A are disposed alternately to each other , and
the respective flat wires appear to be in close contact, the primary coils 1A positioned at both ends of the primary
however in reality gaps are provided between adjacent coil assemblies 1 are disposed further outsides along the
portions of the flat wires . This is also the case in the second axial direction than the secondary coils 2A positioned at
exemplary embodiment onwards . both ends of the secondary coil assemblies 2 . Accordingly ,
[ 0110 ] In the primary coil assemblies 1 , the flat wire when a high frequency current flows in the primary coils , a
between adjacent primary coils 1A configures crossing wires uniform magnetic field generated by the primary coils passes
1B that are pulled out to the outside of the primary coils 1A . through the secondary coils , such that leakage inductance
The crossing wires 1B are formed so as to straddle the can be made extremely small. The degree of coupling
outside of the secondary coils 2A that are adjacent to the between the primary coils and the secondary coils is accord
primary coils 1A . Similarly , in the secondary coil assemblies ingly very close to 1 , thereby enabling an energy transfer
2 the flat wire between adjacent secondary coils 2A config rate from the primary coils to the secondary coils of almost
ures crossing wires 2B that are pulled out to the outside of 100 % , such that loss during energy transfer from the primary
the secondary coils 2A . The crossing wires 2B are formed so coils to the secondary coils can be suppressed to a very small
as to straddle the outside of the primary coils 1A that are amount .
adjacent to the secondary coils 2A . [0115 ] Since the primary coil assemblies 1 have a greater
[0111] As illustrated in FIG . 1 to FIG . 6, at the winding overall number of turns than the secondary coil assemblies
start portion of one of the primary coils 1, the flat wire that 2 , application is suited to situations in which a high voltage ,
forms the pair of primary coil assemblies 1 configures a lead low current high frequency current is input, and a low
wire 1C leading to the outside of the one primary coil 1. At voltage , large current high frequency current is output.
the winding end portion of the one primary coil 1, the flat [0116 ] Moreover, the primary coils 1A and the secondary
wire configures a crossing wire 1D that continues to the coils 2A are of similar internal diameter to each other and are
other of the pair of primary coils 1. At the winding end coaxially disposed . The degree of coupling between the
portion of the other primary coil assembly 1 , the flat wire primary coil assemblies 1 and the secondary coil assemblies
configures a lead wire 1C leading to the outside of the other 2 is accordingly higher, and magnetic flux leakage is even
primary coil assembly 1 similarly to at the winding start smaller than when the primary coils 1A and the secondary
portion of the one primary coil 1. The lead wire 1C is coils 2A have different internal diameters to each other and
connected
?? to an input source that inputs high frequency are not coaxially disposed. The high frequency transformer
current to the primary coils 1 . 10 is therefore suitably employed in high capacity power
[0112 ] Similarly, at the winding start portion of one of the conversion equipment and high capacity power source
secondary coils 2 , the flat wire that forms the pair of equipment.
secondary coil assemblies 2 configures a lead wire 2C [0117 ] Moreover , a higher conversion efficiency can be
leading to the outside of the one secondary coil 2 . At the achieved compared with a high frequency transformer hav
winding end portion of the one secondary coil 2, the flat wire ing two or three primary coils 1A and one or two secondary
configures a crossing wire 2D that continues to the other of coils 2A through which one core 3A is inserted .
the pair of secondary coils 2 . At the winding end portion of [0118 ] Moreover, since the insulation tabs 7A of the
the other secondary coil assembly 2, the flat wire configures insulating members 7 are inserted between the primary coils
a lead wire 2C leading to the outside of the other secondary 1A and the secondary coils 2A , insulation between the
US 2018/0137967 A1 May 17, 2018

primary coils 1A and the secondary coils 2A is more secure is provided with a shell -type ferrite core 4 that includes a
than in a high frequency transformer in which the insulating single circular cylinder shaped central core 4A , and a
members 7 are not inserted between the primary coils 1A primary coil assembly 1 and a secondary coil assembly 2
and the secondary coils 2A . both of which are inserted onto the central core 4A .
[0119 ] In the secondary coils 2A , a flat wire of greater [0125 ] The shell- type ferrite core 4 is configured from a
width and greater thickness than that of the primary coils 1A two -part combination of E - shaped central cores 4B that are
is employed . The high - frequency transformer 10 is accord formed by sintering ferrite into an E -shape and are pressed
ingly suitably employed as a high frequency transformer together along an up - down direction using for example
wherein a high voltage , low current high frequency current clamping fasteners (not illustrated in the drawings ) so as to
is input into the primary coil assemblies 1 and a high face each other. As illustrated in FIG . 8 to FIG . 12, the
frequency current with a large current is obtained from the shell-type ferrite core 4 can be split into the central core 4A
secondary coil assemblies 2 . and an outside core 4C that is positioned so as to enclose the
(0120 ] Due to employing the core - type ferrite core 3 for central core 4A from the outside. Note that instead of
the core, loss can be suppressed to a smaller amount when forming the shell -type ferrite core 4 by combining the facing
employing high frequencies compared to when an iron core E - shaped central cores 4B that are of similar configuration
configured from for example a silicon steel plate is to each other, configuration may also be made wherein the
employed .Moreover, the ratio of the core with respect to the shell-type ferrite core 4 is configured from a combination of
primary coil assemblies 1 and the secondary coil assemblies an E -shaped core corresponding to the central core 4A , the
2 is decreased , thereby leading to stronger copper machine outside core 4C , and a lower portion core , and an I-shaped
characteristics. A large number of turns of the primary coils core corresponding to an upper portion core .
and the secondary coils can accordingly be secured , in 10126 ]. Both the central core 4A and the outside core 4C
particular giving a margin in the density of magnetic flux may be formed in a square column shape, however forming
passing through the inside of the core in cases in which the central core 4A in a circular column shape eliminates
frequency control is performed , such as in a parallel resonant needless gaps between the core - type ferrite core 4 and the
inverter or in a series resonant inverter. The high - frequency primary coil assembly 1 and secondary coil assembly 2 , such
transformer 10 is accordingly suitably applied when a con that the space factor of the total sum of the cross -section area
trol range is widened as far as low frequencies in the region of the primary coils and the secondary coils is close to 100 %
of 10 kHz to 200 kHz). with respect to the area of the winding window , thereby
[0121 ] Moreover, since the primary coil assemblies 1 and contributing to a further reduction in size of the high
the secondary coil assemblies 2 are respectively formed by frequency transformer 20 .
winding a single continuous flat wire edgewise at specific [0127 ] The primary coil assembly 1 is configured by four
intervals, the effort of connecting together separately formed primary coils 1A and the secondary coil assembly 2 is
primary coils 1A and secondary coils 2A to manufacture the configured by three secondary coils 2A . Both the primary
primary coil assemblies 1 and the secondary coil assemblies coil assembly 1 and the secondary coil assembly 2 are
2 is not required . The high - frequency transformer 10 can respectively configured by a single continuous flat wire .
accordingly be manufactured more easily than a high fre [0128 ] The disposal of the primary coils 1A and the
quency transformer in which separately formed primary secondary coils 2A , and the configurations of the primary
coils 1A and secondary coils 2A are connected together to coil assembly 1 and the secondary coil assembly 2 are
configure the primary coil assemblies 1 and the secondary similar to as described above in the first exemplary embodi
coil assemblies 2 . There is moreover no need to for a ment.
connection operation such as soldering in order to connect [0129 ] As illustrated in FIG . 8 to FIG . 12, a winding start
together the primary coils 1A and the secondary coils , thus portion and a winding end portion of the flat wire forming
enabling a lead - free configuration with good environmental the primary coil assembly 1 configure lead wires 1C leading
characteristics. to the outside of the primary coil assembly 1. The lead wires
10122 ] An example has been given above in which the 1C are connected to an input source that inputs high fre
primary coil assemblies 1 and the secondary coil assemblies quency current into the primary coils 1 .
2 are connected in series, however configuration may be [0130 ] Similarly, a winding start portion and a winding
made wherein the primary coil assemblies 1 and the sec end portion of the flat wire forming the secondary coil
ondary coil assemblies 2 are connected in parallel . Configu assembly 2 configure lead wires 2C leading to the outside of
ration may also be made wherein the primary coil assem the secondary coil assembly 2 . The lead wires 2C output a
blies 1 are connected in series and the secondary coil high frequency current with a current and voltage corre
assemblies 2 are connected in parallel, or wherein the sponding to the ratio of turns between the primary coils and
primary coil assemblies 1 are connected in parallel and the the secondary coils .
secondary coil assemblies 2 are connected in series. [0131] As illustrated in FIG . 8 to FIG . 11 , insulating
2 . Second Exemplary Embodiment members 7 are inserted between the primary coil assembly
1 and secondary coil assembly 2 and the central core 4A of
[0123] Explanation follows regarding an example of the shell-type ferrite core 4 . The insulating members 7 are
another embodiment of the high frequency transformer of configured by insulation tabs 7A that extend towards the
the present invention , wherein a primary coil assembly and outside , and an insulation tab retaining member 7B that
a secondary coil assembly are respectively formed from a retains the insulation tabs 7A at specific intervals . The
single flatwire and wherein the secondary coils are inserted insulation tabs 7A of the insulating members 7 are inserted
between the primary coils . between the primary coils 1A and the secondary coils 2A ,
[0124 ] As illustrated in FIG . 8 to FIG . 12 , a high fre and the insulation tab retaining member 7B is inserted
quency transformer 20 of the second exemplary embodiment between the primary coils 1A and secondary coils 2A and the
US 2018/0137967 A1 May 17, 2018

core 3A . Note that in the high frequency transformer 20 , the with rounded apexes and with each edge bulging towards the
insulating members 7 may be inserted from the outside of outside in a circular arc shape in plan view . A bolt insertion
the primary coils 1A and the secondary coils 2A . Moreover , through hole is provided at a central portion , and bolt
as illustrated in FIG . 12 insulation washers 8 that are ring insertion grooves are respectively provided at a central
shaped insulation plates or insulation sheets may be inserted portion on each edge . Fixing bolts 9 are passed through the
between the primary coils 1A and the secondary coils 2A bolt insertion through hole and the bolt insertion grooves ,
instead of inserting the insulating members 7 . thereby fixing together the top plate 5B , the columnar cores
[0132 ] In the high frequency transformer 20 of the second 5A , and the bottom plate 5C .
exemplary embodiment, the shell- type ferrite core 4 is [0138 ] In the three -legged ferrite core 5 , configuration
employed as the core , thereby increasing the ratio of the core may bemade such that the columnar cores 5A can be divided
with respect to the coils in comparison to the high frequency into upper and lower parts along a plane orthogonal to the
transformer of the first exemplary embodiment in which the respective axes of the columnar cores 5A , with the upper
ferrite core is a core -type core , thus leading to stronger iron side halves being integral to the top plate 5B and the lower
machine characteristics . Accordingly, in addition to the side halves being integral to the bottom plate 5C . Moreover,
features of the high frequency transformer of the first the columnar cores 5A may be configured such that instead
exemplary embodiment , there is also the advantageous of having a upper- lower divided configuration , the columnar
effect of being suitably applied in applications with a small cores 5A are integrally formed to one of the top plate 5B and
number turns of the primary coils and the secondary coils , the bottom plate 5C such that the other of the top plate 5B
in particular in high frequency inverters ( in the region of 50 and the bottom plate 5C can be separated from the columnar
kHz to 1 MHz). cores 5A .
[ 0133] Moreover, since the primary coil assembly 1 and (01391. One of the three columnar cores 5A is mounted
the secondary coil assembly 2 are respectively formed by with the primary coil assembly 11 and the secondary coil
winding a single continuous flat wire at specific intervals the
effort of connecting together separately formed primary assembly 21, one of the other columnar cores 5A is mounted
coils 1A and secondary coils 2A to manufacture the primary with the primary coil assembly 12 and the secondary coil
coil assembly 1 and the secondary coil assembly 2 is not assembly 22 , and the other of the columnar cores 5A is
required. The high frequency transformer 20 is accordingly mounted with the primary coil assembly 13 and the second
easily manufactured in comparison to high frequency trans ary coil assembly 23 .
formers in which separately formed primary coils 1A and [0140] As illustrated in FIG . 14 to FIG . 18 , the primary
secondary coils 2A are respectively connected together to coil assemblies 11, 12 , 13 and the secondary coil assemblies
configure the primary coil assembly 1 and the secondary coil 21 , 22 , 23 are respectively configured by a single continuous
assembly 2 . Good environmental characteristics are also flat wire . The primary coil assemblies 11 , 12, 13 are respec
exhibited due to having a lead - free configuration . tively formed with four primary coils 1A of four turns each ,
formed in uniform intervals such that in two adjacent
3 . Third Exemplary Embodiment primary coils 1A , a winding end portion of one of the
[0134 ] Explanation follows regarding a three phase high adjacent primary coils 1A opposes a winding start portion of
frequency transformer included in the high frequency trans the other of the adjacent primary coils 1A . Similarly , the
former of the present invention , wherein the primary coil secondary coil assemblies 21 , 22 , 23 are respectively formed
assembly and the secondary coil assembly are respectively with three secondary coils 2A of three turns, formed in
formed from a single flat wire , and wherein the secondary uniform intervals such that in two adjacent secondary coils
coils are inserted between the primary coils .
2A , a winding end portion of one of the adjacent secondary
[0135 ] As illustrated in FIG . 14 to FIG . 17 , in a three phase coils 2A opposes a winding start portion of the other of the
high frequency transformer 30 according to the third exem adjacent secondary coils 2A .
plary embodiment a three phase , three -legged ferrite core 5 [0141] The flat wire configuring the primary coil assem
is inserted into primary coil assemblies 11 , 12 , 13 and blies 11 , 12 , 13 configures crossing wires 1B pulled out to
secondary coil assemblies 21, 22 , 23. Two insulating mem the outside of the primary coils 1A at portions between the
bers 7 are fitted into each of the respective primary coil primary coils 1A . The crossing wires 1B are formed so as to
assemblies 11 , 12 , 13 and secondary coil assemblies 21 , 22 , straddle the outside of the adjacent secondary coils 2A .
23 at symmetrical positions about the axes of respective Similarly, the flat wire configuring the secondary coil assem
columnar cores 5A , which are described later. The insulating blies 21 , 22 , 23 configures crossing wires 2B pulled out to
members 7 are of similar configuration to those described the outside of the secondary coils 2A at portions between the
above in the first exemplary embodiment. secondary coils 2A . The crossing wires 2B are formed so as
[0136 ] The three- legged ferrite core 5 is included in the to straddle the outside of the adjacent primary coils 1A .
ferrite core of the high frequency transformer of the present [0142 ] The insulating members 7 are inserted between the
invention , and as illustrated in FIG . 14 to FIG . 17 , the primary coil assemblies 11 , 12 , 13 , the secondary coil
three - legged ferrite core 5 includes three columnar cores 5A assemblies 21, 22, 23 , and the columnar cores 5A . The
that are formed from ferrite and are disposed at 120 degree insulating members 7 are of similar configuration to that
intervals around the circumference of the three - legged fer described above in the first exemplary embodiment and the
rite core 5 , a plate shaped top plate 5B that is formed from second exemplary embodiment. Note that in the high fre
ferrite and is coupled to upper ends of the three columnar quency transformer 30 the insulating members 7 may be
cores 5A , and a bottom plate 5C that is formed from ferrite inserted from the outside of the primary coils 1A and the
and is coupled to lower ends of the three columnar cores 5A . secondary coils 2A . Moreover, as illustrated in FIG . 17
[ 0137 ] The top plate 5B and the bottom plate 5C are configuration may be made wherein insulation washers 8
respectively configured in an equilateral triangular shape that are ring shaped insulation plates or insulation sheets are
US 2018/0137967 A1 May 17, 2018

inserted between the primary coils 1A and the secondary harmonics contained in the input circulate in the primary
coils 2A instead of inserting the insulating members 7 . coil assemblies 11 , 12 , 13 that are configured with a delta
[0143] As illustrated in FIG . 14 to FIG . 17 , in the primary connection .
coil assemblies 11 , 12, 13 , the winding start portions and the [0148 ] The high frequency transformer 30 is suitably
winding end portions of the respective primary coil assem employed in applications in which a high voltage alternating
blies 11 , 12 , 13 configure lead wires 1C leading out to the current is output from the secondary coil assemblies 21 , 22 ,
outside of the primary coil assemblies 11 , 12 , 13 . One of the 23 side by configuring the primary coil assemblies 11 , 12 , 13
lead wires 1C of each of the primary coil assemblies 11, 12 , with a Y connection and configuring the secondary coil
13 is bent upwards and respectively connected to a connec assemblies 21, 22, 23 with a delta connection . Moreover,
tion ring 6 that is a circular ring shaped conducting body. even when unwanted harmonics are included in the high
The other lead wires 1C of the respective primary coil frequency current that is input on the primary side, since the
assemblies 11 , 12 , 13 respectively configure a U phase input harmonics included in the input circulate in the secondary
terminal, a V phase input terminal and a W phase input coil assemblies 21 , 22 , 23 that are configured with a delta
terminal. The primary coil assemblies 11 , 12 , 13 are accord connection , the harmonics are not included in the high
ingly configured with a Y connection , as illustrated in FIG . frequency current that is output from the secondary side.
18 . [0149] Moreover, the high frequency transformer 30 is
[0144 ] As illustrated in FIG . 14 to FIG . 17 , in the sec suitably employed in applications in which electrical energy
ondary coil assemblies 21 , 22 , 23 the winding start portions is passed back and forth between two mutually insulated
and the winding end portions of the respective secondary circuits at large currents and high voltages by configuring
coil assemblies 21, 22, 23 configure lead wires 2C leading both the primary coil assemblies 11, 12 , 13 and the second
out to the outside of the secondary coil assemblies 21, 22 , ary coil assemblies 21, 22 , 23 with delta connections.
23 . The winding end lead wire 2C of the secondary coil Moreover , even when unwanted harmonics are included in
assembly 21 is connected to the winding start lead wire 2C the high frequency current input on the primary side, since
of the secondary coil assembly 22 , the winding end lead wire the harmonics included in the input circulate in the primary
2C of the secondary coil assembly 22 is connected to the coil assemblies 11 , 12 , 13 that are connected with a delta
winding start lead wire 2C of the secondary coil assembly connection and in the secondary coil assemblies 21 , 22 , 23
23 , and the winding end lead wire 2C of the secondary coil that are similarly configured with a delta connection , the
assembly 23 is connected to the lead wire 2C of the harmonics are not included in the high frequency current
secondary coil assembly 21 . A connection portion between that is output from the secondary side .
the secondary coil assembly 23 and the secondary coil
assembly 21 is connected to a u phase , a connection portion 4. Fourth Exemplary Embodiment
between the secondary coil assembly 21 and the secondary
coil assembly 22 is connected to a v phase , and a connection [0150 ] Explanation follows regarding an example of a
portion between the secondary coil assembly 22 and the high frequency transformer of the present invention wherein
secondary coil assembly 23 is connected to a w phase. The primary coil assemblies and secondary coil assemblies are
secondary coil assemblies 21 , 22 , 23 are accordingly con respectively formed from a single flat wire , and the primary
figured with a delta connection , as illustrated in FIG . 18 . coils are inserted between the secondary coils in the primary
[0145 ] In the three phase high frequency transformer 30 , coil assemblies and the secondary coil assemblies .
the primary coil assemblies 11 , 12 , 13 are thus configured [0151] As illustrated in FIG . 19 to FIG . 23 , a high fre
with a Y connection , and the secondary coil assemblies 21, quency transformer 40 of the fourth exemplary embodiment
22 , 23 are configured with a delta connection , however is provided with a core - type ferrite core 3 similar to that of
configuration may bemade wherein the primary coil assem the first exemplary embodiment, and primary coil assem
blies 11 , 12 , 13 are configured with a delta connection and blies 1 and secondary coil assemblies 2 respectively
the secondary coil assemblies 21, 22 , 23 are configured with mounted onto 2 cores 3A .
a Y connection , or configuration may be made wherein each [0152 ] The primary coil assemblies 1 are formed from a
of the primary coil assemblies 11 , 12 , 13 and the secondary single flat wire as described above , and are respectively
coil assemblies 21, 22, 23 are configured with either a delta formed with three primary coils 1A of three turns each ,
connection or a Y connection . disposed with uniform intervals therebetween . The three
[0146 ] The high frequency transformer 30 of the third primary coils 1A are formed such that a winding end portion
exemplary embodiment is suitably employed in applications of a first of mutually adjacent primary coils 1A opposes a
in which high voltage electrical energy is passed back and winding start portion of the other of the mutually adjacent
forth between two mutually insulated circuits by configuring primary coils 1A .
both the primary coil assemblies 11 , 12 , 13 and the second [0153] The secondary coil assemblies 2 are also formed
ary coil assemblies 21, 22, 23 with Y connections. from a single flat wire as described above , and each of the
[0147 ] The high frequency transformer 30 is suitably secondary coil assemblies 2 is formed with four secondary
employed in applications in which an alternating current of coils 2A of four turns, disposed with uniform intervals
a large current is output on the secondary coil assemblies 21 , therebetween . The four secondary coils 2A are formed such
22 , 23 side by configuring the primary coil assemblies 11 , that a winding end portion of a first of mutually adjacent
12 , 13 with a delta connection and configuring the secondary secondary coils 2A opposes a winding start portion of the
coil assemblies 21 , 22 , 23 with a Y connection . Moreover, other of the mutually adjacent secondary coils 2A . Note that
when unwanted harmonics are contained in the high fre the number of turns of the primary coils 1A and the
quency current that is input on the primary side, a high secondary coils 2A does not necessarily have to be the
frequency current that does not contain the unwanted har - number of turns illustrated in FIG . 19 to FIG . 23 , and may
monics can be obtained from the secondary side since the be determined based on the ratio between the high frequency
US 2018/0137967 A1 May 17, 2018

current input into the primary coil assemblies 1 and the high coil assemblies 1 are connected together in parallel and the
frequency current output from the secondary coils 2A . secondary coil assemblies are connected together in series.
101541 Accordingly , as illustrated in FIG . 24 the primary
coils 1A and the secondary coils 2A are respectively con 5 . Fifth Exemplary Embodiment
ent
figured in series in both the primary coil assemblies 1 and
the secondary coil assemblies 2 . The pair of primary coil [0161] Explanation follows regarding another example of
assemblies 1 and the pair of secondary coil assemblies 2 are a high frequency transformer of the present invention,
also respectively connected in series . wherein a primary coil assembly and a secondary coil
[0155 ] As illustrated in FIG . 19 to FIG . 23 , the secondary assembly are respectively formed from a single flat wire, and
coils 2A are formed from surface insulated flat wire wound the primary coils are inserted between the secondary coils.
edgewise , and the primary coils 1A are similarly formed As illustrated in FIG . 25 to FIG . 28 , a high frequency
from surface insulated flat wire wound edgewise. Note that transformer 50 of the fifth exemplary embodiment is pro
winding edgewise refers to a winding method in which the vided with a shell-type ferrite core 4 provided with a single
flat wire is wound along the width direction .However, in the circular cylinder shaped central core 4A , and a primary coil
primary coils 1A , flat wire that is greater in both width and assembly 1 and a secondary coil assembly 2 that are
thickness than those of the secondary coils 2A is employed . mounted onto the central core 4A .
[ 0156 ] The primary coil assemblies 1 and the secondary [0162] The shell -type ferrite core 4 can be split into the
coil assemblies 2 are combined together such that the central core 4A and an outside core 4C positioned so as to
primary coils 1A configuring the primary coil assemblies 1 enclose the central core 4A from the outside similarly to in
are inserted between one and another of the mutually the high frequency transformer 20 of the second exemplary
adjacent secondary coils 2A of the secondary coil assemblies embodiment. Both the central core 4A and the outside core
2 , and such that the winding start portion of each of the 4C are configured similarly to as described above in the
primary coils 1A opposes the winding end portion of the one second exemplary embodiment.
secondary coil 2A , and the winding end portion of the [0163] As illustrated in FIG . 25 to FIG . 28 , the primary
primary coil opposes the winding start portion of the other coil assembly 1 and the secondary coil assembly 2 are
secondary coil 2A . respectively formed from a single continuous flat wire . The
10157) Other than in the points described above, the high primary coil assembly 1 is formed with three primary coils
frequency transformer 40 of the fourth exemplary embodi 1A of three turns each , formed in uniform intervals such that
ment is similar to the high -frequency transformer 10 of the a winding end portion of one of adjacent primary coils 1A
first exemplary embodiment . opposes a winding start portion of the other of the adjacent
[ 0158 ] Similarly to the high - frequency transformer 10 of primary coils 1A . The secondary coil assembly 2 is formed
the first exemplary embodiment, since in the high frequency with four secondary coils 2A of four turns each , formed in
transformer 40 of the fourth exemplary embodiment the pair uniform intervals such that a winding end portion of one of
of primary coil assemblies 1 and the pair of secondary coil adjacent secondary coils 2A opposes a winding start portion
assemblies 2 are respectively formed by winding a single of the other of the adjacent secondary coils 2A .
continuous flat wire at a specific interval, the effort of [0164 ] The primary coil assembly 1 and the secondary coil
connecting together separately formed primary coils 1A and assembly 2 are combined together such that the primary
secondary coils 2 A in order to manufacture the primary coil coils 1A are inserted between adjacent secondary coils 2A ,
assemblies 1 and the secondary coil assemblies 2 is not and the winding start portion of each of the respective
required . The high - frequency transformer 40 can accord primary coils 1A of the primary coil assembly 1 opposes the
ingly be manufactured more easily than a high frequency winding end portion of one of adjacent secondary coils 2A
transformer in which separately formed primary coils 1A of the secondary coil assembly 2 , and the winding end
and secondary coils 2A are connected together to configure portion of the primary coil 1A opposes the winding start
the primary coil assemblies 1 and the secondary coil assem portion of the other of the adjacent secondary coils 2A . All
blies 2 . Environmental characteristics are moreover good of the primary coils 1A and the secondary coils 2A are
due to having a lead -free configuration . moreover arrayed coaxially to one another.
[0159 ] Since the secondary coils 2A are disposed at both [0165 ] The flatwire configuring the primary coil assembly
ends in the high frequency transformer 40, the overall 1 configures crossing wires 1B that are pulled out to the
secondary coil assemblies 2 can easily be configured with a outside of the primary coils 1A at portions between the
greater number of turns of the flat wire than the primary coil primary coils 1A . The crossing wires 1B are formed so as to
assemblies 1 in comparison to the high -frequency trans straddle the outside of the secondary coils 2A adjacent to the
former 10 of the first exemplary embodiment. The high primary coils 1A . Similarly, the flat wire configuring the
frequency transformer 40 is accordingly suitably employed
in applications in which a high voltage high frequency secondary coil assembly 2 configures crossing wires 2B that
current is output. are pulled out to the outside of the secondary coils 2A at
[0160 ] Explanation has been given above regarding an portions between the secondary coils 2A .
example in which both the primary coil assemblies 1 and the [0166 ] As illustrated in FIG . 29 , the primary coils 1A of
secondary coil assemblies 2 are respectively connected in the primary coil assembly 1 are accordingly configured in
series, however the primary coil assemblies 1 and the series , and the secondary coils 2A of the secondary coil
secondary coil assemblies 2 may be connected together in assembly 2 are also configured in series .
parallel. Moreover, configuration may be made wherein the [0167 ] As illustrated in FIG . 25 to FIG . 28, portions of the
primary coil assemblies 1 are connected together in series flat wire forming the primary coil assembly 1 configure lead
and the secondary coil assemblies are connected together in wires 1C that lead out to the outside of the primary coils 1
parallel, or configuration may be made wherein the primary at the winding start portion and winding end portion of the
US 2018/0137967 A1 May 17 , 2018

primary coil assembly 1 . The lead wires 1? are connected to secondary coil assemblies 21 , 22, 23 at symmetrical posi
an input source that inputs a high frequency current into the tions about the axis of respective columnar cores 5A , which
primary coils 1. is described later.
[ 0168 ] Similarly, portions of the flat wire forming the [0175 ] The configuration of the three - legged ferrite core 5 ,
secondary coil assembly 2 configure lead wires 2C that lead and the relationships between the three - phase ferrite core 5 ,
out to the outside of the secondary coils 2 at the winding start the primary coil assemblies 11, 21 , 13 and the secondary coil
portion and the winding end portion . High frequency current assemblies 21 , 22 , 23 are similar to as described above in the
with a voltage and current corresponding to the ratio of the third exemplary embodiment.
number of turnsbetween the primary coils and the second 101761 As illustrated in FIG . 30 to FIG . 34 , the primary
ary coils is output from the lead wires 2C . coil assemblies 11 , 12 , 13 and the secondary coil assemblies
[0169 ] Insulating members 7 are inserted between the 21 , 22 , 23 are respectively formed from a single continuous
primary coil assembly 1 and secondary coil assembly 2 , and flat wire . The primary coil assemblies 11 , 12, 13 are respec
the central core 4A of the shell -type ferrite core 4 . The tively formed with three primary coils 1A of three turns
insulating members 7 are configured by insulation tabs 7A each , formed in uniform intervals such that in two adjacent
that extend towards the outside , and an insulation tab primary coils 1A , a winding end portion of one of the
retaining member 7B that retains the insulation tabs 7A at adjacent primary coils 1A opposes a winding start portion of
specific intervals . The insulation tabs 7A of the insulating the other of the adjacent primary coils 1A . Similarly , the
members 7 are inserted between the primary coils 1A and the secondary coil assemblies 21, 22, 23 are respectively formed
secondary coils 2A , and the insulation tab retaining member with four secondary coils 2A of four turns each , formed in
7B is inserted between the primary coils 1A and the sec uniform intervals such that in two adjacent secondary coils
ondary coils 2A and the core 3A . 2A , a winding end portion of one of the adjacent secondary
[0170 ] The high frequency transformer 50 of the fifth coils 2A opposes a winding start portion of the other of the
exemplary embodiment moreover employs the shell - type adjacent secondary coils 2A .
ferrite core 4 as the core , similarly to the high frequency [0177 ] The flat wire configuring the primary coil assem
transformer 20 of the second exemplary embodiment, blies 11 , 12 , 13 configures crossing wires 1B that are pulled
thereby increasing the ratio of the core with respect to the out to the outside of the primary coils 1A at portions between
coils in comparison to the high frequency transformer of the the primary coils 1A . The crossing wires 1B are formed so
first exemplary embodiment that employs a core -type core as to straddle the outside of the adjacent secondary coil 2A .
as the ferrite core, thereby strengthening the iron machine Similarly, the flat wire configuring the secondary coil assem
blies 21 , 22 , 23 configures crossing wires 2B that are pulled
characteristics. Accordingly , in addition to the features of the out to the outside of the secondary coils 2A at portions
high frequency transformer of the fourth exemplary embodi between the secondary coils 2A . The crossing wires 2B are
ment, there is also the advantageous effect of being suitably formed so as to straddle the outside of the adjacent primary
applied in applications with a small number of turns of the coil 1A .
primary coils and the secondary coils, in particular in high
frequency inverters ( in the region of 50 kHz to 1 MHz). [0178 ] The insulating members 7 are disposed similarly to
10171] Moreover, similarly to the high frequency trans as described above in the third exemplary embodiment.
former 20 of the second exemplary embodiment, the high Moreover, as illustrated in FIG . 33 , configuration may be
frequency transformer 50 has a lead -free configuration , thus made wherein insulation washers 8 that are insulation plates
or insulation sheets are inserted between the primary coils
giving good environmental characteristics. 1A and the secondary coils 2A instead of the insulating
[0172] In the high frequency transformer 50 the secondary members 7 .
coils 2A are disposed at both ends , thereby making it easy [0179 ] As illustrated in FIG . 30 to FIG . 33, in the primary
to configure a greater number of turns of the flat wire in the coil assemblies 11 , 12 , 13 the winding start portions and the
overall secondary coil assembly 2 than the number of turns winding end portions of the respective primary coil assem
of the overall primary coil assembly 1 than in the high blies 11 , 12, 13 configure lead wires 1C leading out to the
frequency transformer 20 of the second exemplary embodi outside of the primary coil assemblies 11 , 12 , 13 . The
ment. The high frequency transformer 50 is accordingly winding end lead wire 1C of the primary coil assembly 11
suitably employed in applications in which a high voltage is connected to the winding start lead wire 1C of the primary
high frequency current is output. coil assembly 12 , the winding end lead wire 1C of the
primary coil assembly 12 is connected to the winding start
6 . Sixth Exemplary Embodiment lead wire 1C of the primary coil assembly 13 , and the
winding end lead wire 1C of the primary coil assembly 13
[ 0173] Explanation follows regarding a three phase high is connected to the lead wire 1C of the primary coil assembly
frequency transformer included in the high frequency trans 11 . A connection portion between the primary coil assembly
former of the present invention wherein the primary coil 13 and the primary coil assembly 11 is connected to a u
assemblies and the secondary coil assemblies are respec phase , a connection portion between the primary coil assem
tively formed from a single flat wire , and the primary coils bly 11 and the primary coil assembly 12 is connected to a v
are inserted between the secondary coils. phase, and a connection portion between the primary coil
[ 0174 ] As illustrated in FIG . 30 to FIG . 34 , in a three phase assembly 12 and the primary coil assembly 13 is connected
high frequency transformer 60 of the sixth exemplary to a w phase . The primary coil assemblies 11 , 12 , 13 are
embodiment, a three phase , three -legged ferrite core 5 is accordingly configured with a delta connection , as illus
inserted into primary coil assemblies 11, 12 , 13 and second trated in FIG . 35 .
ary coil assemblies 21, 22 , 23 . Two insulatingmembers 7 are [0180 ] However, as illustrated in FIG . 30 to FIG . 33, in the
fitted into each of the primary coil assemblies 11 , 12 , 13 and secondary coil assemblies 21, 22 , 23 the winding start
US 2018/0137967 A1 May 17, 2018

portions and the winding end portions of the respective assemblies 21, 22 , 23 that are similarly configured with a
secondary coil assemblies 21, 22 , 23 configure lead wires 2C delta connection , the harmonics are not included in the high
leading out to the outside of the secondary coil assemblies frequency current that is output from the secondary side .
21 , 22, 23 . One of the lead wires 2C of each of the secondary
coil assemblies 21, 22 , 23 is bent upwards and respectively 7 . Seventh Exemplary Embodiment
connected to a connection ring 6 that is a circular ring [0186 ] Explanation follows regarding an example of a
shaped conducting body. The other lead wires 2C of the high frequency transformer of the present invention wherein
respective secondary coil assemblies 21, 22 , 23 respectively a primary coil assembly and a secondary coil assembly are
configure a U phase input terminal, a V phase input terminal formed by inserting the primary coils between the secondary
and a W phase input terminal. The secondary coil assemblies coils , and connecting together the primary coils and the
21 , 22 , 23 are accordingly configured with a Y connection , secondary coils at crossing wires.
as illustrated in FIG . 35 . [0187 ] As illustrated in FIG . 35 and FIG . 36 , a high
[0181] In the three phase high frequency transformer 60 , frequency transformer 70 of the seventh exemplary embodi
the primary coil assemblies 11 , 12 , 13 are thus configured ment is provided with a shell-type ferrite core 4 including a
with a delta connection , and the secondary coil assemblies single circular cylinder shaped central core 4A , and a
21, 22 , 23 are configured with a Y connection , however primary coil assembly 1 and a secondary coil assembly 2
configuration may be made wherein the primary coil assem into which the central core 4A is inserted.
blies 11 , 12 , 13 are configured with a Y connection and the 10188 ] The shell-type ferrite core 4 is configured similarly
secondary coil assemblies 21, 22 , 23 are configured with a to as described above in the second exemplary embodiment
delta connection , or configuration may bemade wherein the and the fifth exemplary embodiment.
primary coil assemblies 11 , 12 , 13 and the secondary coil [0189] The primary coil assembly 1 is configured by three
assemblies 21, 22 , 23 are both configured with either a delta primary coils 1A of three turns each arrayed in series, and
connection or a Y connection . the secondary coil assembly 2 is configured by four second
[ 0182 ] The high frequency transformer 60 of the sixth ary coils 2A of four turns each arrayed in series.
exemplary embodiment is suitably employed in applications [0190] Start end portions and finish end portions of the flat
in which high voltage electrical energy is passed back and wire configuring the primary coils 1A configure crossing
forth between twomutually insulated circuits by configuring wires 1B that are pulled out to the outside of the primary
both the primary coil assemblies 11 , 12 , 13 and the second coils 1A . Similarly , start end portions and finish end portions
ary coil assemblies 21 , 22 , 23 with Y connections. of the flat wire configuring the secondary coils 2A configure
[0183] The high frequency transformer 60 is suitably crossing wires 2B that are pulled out to the outside of the
employed in applications in which a large alternating current secondary coils 2A . The primary coils 1A are connected
is output on the secondary coil assemblies 21 , 22 , 23 side by together by the crossing wires 1B . Similarly, the secondary
configuring the primary coil assemblies 11, 12 , 13 with a coils 2A are connected together by the crossing wires 2B .
delta connection and configuring the secondary coil assem The means for connecting together the primary coils 1A and
blies 21, 22 , 23 with a Y connection . Moreover, when the means for connecting together the secondary coils 2A
unwanted harmonics are included in the high frequency include for example soldering , brazing , welding and bolts .
current that is input on the primary side , a high frequency [0191 ] The winding start side crossing wire 1B of the
current that does not include the unwanted harmonics can be primary coil 1A positioned at one end of the primary coil
obtained from the secondary side since the harmonics assembly 1 and the winding end side crossing wire 1B of the
included in the input circulate in the primary coil assemblies primary coil 1A positioned at the other end of the primary
11 , 12 , 13 that are configured with a delta connection . coil assembly 1 respectively configure lead wires 1? . Simi
[ 01841. The high frequency transformer 60 is suitably larly , the winding start side crossing wire 2B of the second
employed in applications in which a high voltage alternating ary coil 2A positioned at one end of the secondary coil
current is output on the secondary coil assemblies 21 , 22 , 23 assembly 2 and the winding end side crossing wire 2B ofthe
side by configuring the primary coil assemblies 11, 12 , 13 secondary coil 2A positioned at the other end of the sec
with a Y connection and configuring the secondary coil ondary coil assembly 2 respectively configure lead wires 2C .
assemblies 21, 22 , 23 with a delta connection . Moreover,
as [0192 ] Moreover, the primary coil assembly 1 and the
even when unwanted harmonics are included in the high secondary coil assembly 2 are combined together such that
frequency current that is input on the primary side, since the the primary coils 1A are inserted between adjacent second
harmonics included in the input circulate in the secondary ary coils 2A , and the winding start portions of the respective
coil assemblies 21, 22 , 23 that are configured with a delta primary coils 1A of the primary coil assembly 1 oppose the
connection , the harmonics are not included in the high winding end portion of one of adjacent secondary coils 2A
frequency current that is output from the secondary side . of the secondary coil assembly 2 , and the winding end
[ 0185 ] Moreover, the high frequency transformer 60 can portion of the primary coil 1A opposes the winding start
be suitably employed in applications in which electrical portion of the other of the adjacent secondary coils 2A . All
energy is passed back and forth between two mutually of the primary coils 1A and the secondary coils 2A are
insulated circuits at large currents and high voltages by moreover arrayed so as to be coaxial to each other.
configuring both the primary coil assemblies 11, 12 , 13 and [0193] The high frequency transformer 70 of the seventh
the secondary coil assemblies 21 , 22 , 23 with delta connec exemplary embodiment employs the shell-type ferrite core 4
tions. Moreover, even when unwanted harmonics are as the core , similarly to the high frequency transformer 20
included in the high frequency current that is input on the of the second exemplary embodiment, thereby increasing
primary side , since the harmonics included in the input the ratio of the core with respect to the coils in comparison
circulate in the primary coil assemblies 11, 12 , 13 that are to high frequency transformers in which the ferrite core is a
connected with a delta connection and in the secondary coil core -type core, thereby strengthening the iron machine char
US 2018/0137967 A1 May 17, 2018

acteristics. There is accordingly the advantageous effect of 9. Ninth Exemplary Embodiment

being suitably applied in applications with a small number [0201 ] Explanation follows regarding yet another example
of turns of the primary coils and the secondary coils , in of a high frequency transformer of the present invention
particular in high frequency inverters in the region of 50 wherein the primary coil assembly and the secondary coil
kHz to 1 MHz). assembly are formed by inserting the primary coils between
the secondary coils, and the primary coils and the secondary
8 . Eighth Exemplary Embodiment coils are respectively connected together at crossing wires .
[0194 ] Explanation follows regarding another example of [0202] As illustrated in FIG . 41 and FIG . 42 , a high
a high frequency transformer of the present invention frequency transformer 90 of the ninth exemplary embodi
wherein the primary coil assembly and the secondary coil ment is a core - type transformer provided with a shell-type
assembly are formed by inserting the primary coils between ferrite core 4 including a single circular cylinder shaped
the secondary coils, and the primary coils and the secondary central core 4A , and a primary coil assembly 1 and a
coils are respectively connected together at crossing wires. secondary coil assembly 2 into which the central core 4A is
inserted .
[0195 ] As illustrated in FIG . 38 and FIG . 39 , a high [0203] As illustrated in FIG . 41 to FIG . 43 , the secondary
frequency transformer 80 of the eighth exemplary embodi coil assembly 2 is configured by in series connecting
ment is provided with a shell-type ferrite core 4 including a together four secondary coils 2 A that configure the second
single circular cylinder shaped central core 4A , and a ary coil assembly 2 with crossing wires 2B . The winding
primary coil assembly 1 and a secondary coil assembly 2 start portion of a first tier secondary coil 2A and the winding
into which the central core 4A is inserted . end portion of a fourth tier secondary coil 2A respectively
[0196 ] The shell-type ferrite core 4 is configured similarly configure lead wires 2C .
to as described above in the second exemplary embodiment [0204] However, a primary coil assembly 1 is configured
and the fifth exemplary embodiment. by connecting together in parallel three primary coils 1A that
[0197] As illustrated in FIG . 38 to FIG . 40, in the high configure the primary coil assembly 1 with crossing bars 1E
frequency transformer 80 of the eighth exemplary embodi at one and the other crossing wires 1B . The winding start
ment, a primary coil assembly 1 is configured by three portion of a first tier primary coil 1A and the winding end
primary coils 1A of three turns each that are connected portion of a third tier primary coil 1A configure lead wires
together in parallel by crossing bars 1E at respective pairs of 2C .
crossing wires 1B . Similarly , a secondary coil assembly 2 is [0205 ] In the high frequency transformer 90 , the primary
configured by four secondary coils 2A of four turns each that coil assembly 1 and the secondary coil assembly 2 are
are connected together in parallel by crossing bars 2E at combined together similarly to in the high frequency trans
respective pairs of crossing wires 2B . formers of the seventh exemplary embodiment and the
[0198 ] In the primary coil assembly 1 , the winding start eighth exemplary embodiment, such that the primary coils
portion crossing wire 1B of a first tier primary coil 1A and 1A are inserted between adjacent secondary coils 2A , and
the winding end portion crossing wire 1B of a third tier the winding start portions of the respective primary coils 1A
primary coil 1A respectively configure lead wires 1? . Simi of the primary coil assembly 1 oppose the winding end
larly, in the secondary coil assembly 2 the winding start portion of one of adjacent secondary coils 2A of the sec
portion crossing wire 2B of a first tier secondary coil 2A and ondary coil assembly 2 , and the winding end portion of the
primary coil 1A opposes the winding start portion of the
the winding end portion crossing wire 2B of a fourth tier other of the adjacent secondary coils 2A . All of the primary
secondary coil 2A respectively configure lead wires 2C . coils 1A and the secondary coils 2A are moreover arrayed so
[0199] The primary coil assembly 1 and the secondary coil as to be coaxial to each other .
assembly 2 are combined together similarly to the high [0206 ] Note that in the high frequency transformer 90 ,
frequency transformer 70 of the seventh exemplary embodi configuration may be made wherein the primary coils 1A are
ment, such that the primary coils 1A are inserted between connected in series together and the secondary coils 2A are
adjacent secondary coils 2A , and the winding start portions connected together in parallel instead of connecting together
of the respective primary coils 1A of the primary coil the primary coils 1A in parallel and in series connecting
assembly 1 oppose the winding end portion of one of together the secondary coils 2A .
adjacent secondary coils 2A of the secondary coil assembly [0207 ] As illustrated in FIG . 43, in the high frequency
2 , and the winding end portion of the primary coil 1A transformer 90 the three primary coils 1A configuring the
opposes the winding start portion of the other of the adjacent primary coil assembly 1 are connected together in parallel,
secondary coils 2A . All of the primary coils 1A and the and the four secondary coils 2A configuring the secondary
secondary coils 2A are moreover arrayed so as to be coaxial coil assembly 2 are connected in series together. The high
to each other. frequency transformer 90 is therefore particularly suitably
[ 0200 ] As illustrated in FIG . 40 , the high frequency trans employed in applications in which a low voltage high
former 80 is configured with both the three primary coils 1A frequency current is input into the primary coil assembly 1
configuring the primary coil assembly 1 and the four sec and a high voltage high frequency current is output from the
ondary coils 2A configuring the secondary coil assembly 2 secondary coils .
respectively connected together in parallel. The high fre [0208 ] Explanation has been given above regarding
quency transformer 80 is accordingly particularly suitably embodiments of high frequency coils in which the primary
employed in applications in which a low voltage , large coils are inserted between the secondary coils , with both the
current high frequency current is input into the primary side primary coils 1A and the secondary coils 2A respectively
and an even lower voltage and larger current high frequency connected in series together , with both the primary coils 1A
current is output from the secondary side . and the secondary coils 2A respectively connected together
US 2018/0137967 A1 May 17, 2018
14

in parallel, and with the primary coils 1A connected together [0216 ] As illustrated in FIG . 47 , the primary coils 1A of
in parallel and the secondary coils 2A connected in series the primary coil assembly 1 are accordingly arrayed in
together, however the present invention also includes high series , and the secondary coils 2A of the secondary coil
frequency coils in which the primary coils 1A are connected assembly 2 are also arrayed in series.
in series together and the secondary coils 2A are connected [0217 ] As illustrated in FIG . 44 to FIG . 46 , out of the three
together in parallel. primary coils 1A that form the primary coil assembly 1 , the
winding start portion of a first tier primary coil 1A and the
10 . Tenth Exemplary Embodiment flat wire winding end portion of a third tier primary coil 1A
[ 0209 ] Explanation follows regarding an example of a out of the three primary coils 1A are pulled out to the outside
high frequency transformer of the present invention wherein of the primary coils 1 to configure lead wires 1? . The lead
the high frequency transformer is configured with primary wires 1? are connected to an input source that inputs a high
coils inserted between the secondary coils , the primary coil frequency current into the primary coils 1.
assembly is formed by in series connecting together plural of [0218 ] Similarly, the winding start portion and the wind
the primary coils, and the secondary coil assembly is formed ing end portion of the flat wire that forms the secondary coil
from a single flat wire . assembly 2 configure lead wires 2C that are pulled out to the
[0210] As illustrated in FIG . 44 to FIG . 47 , a high fre outside of the secondary coils 2 . A high frequency current
quency transformer 100 of the tenth exemplary embodiment that has a voltage and current corresponding to the ratio of
is provided with a shell-type ferrite core 4 including a single turns between the primary coils 1 and the secondary coils 2
circular cylinder shaped central core 4A , and a primary coil is output from the lead wires 2C .
assembly 1 and a secondary coil assembly 2 into which the [0219 ] Insulating members 7 are inserted between the
central core 4A is inserted . The shell -type ferrite core 4 is primary coil assembly 1 , the secondary coil assembly 2 and
configured similarly to as described above in the second the central core 4A of the shell -type ferrite core 4 similarly
exemplary embodiment and the fifth exemplary embodi to in the high frequency transformer of the fourth exemplary
ment. embodiment. Insulation tabs are configured similarly to as
[0211] As illustrated in FIG . 44 to FIG . 47 , in the primary described above in the fourth exemplary embodiment.
coil assembly 1 , three primary coils 1A of three turns each [0220 ] The high frequency transformer 100 of the tenth
are connected in series and arrayed in uniform intervals such exemplary embodiment employs the shell-type ferrite core 4
that the winding end portion of one ofadjacent primary coils as the core similarly to the high frequency transformer 20 of
1A opposes the winding start portion of the other of the the second exemplary embodiment, thereby increasing the
adjacent primary coils 1A . ratio of the core with respect to the coils in comparison to
[0212 ] On the other hand , the secondary coil assembly 2 high frequency transformers in which the ferrite core is a
is formed from a single flat wire as described above, and is core -type core , thereby strengthening the iron machine char
formed with four secondary coils 2A of four turns each , acteristics. There is accordingly the advantageous effect of
formed in uniform intervals such that the winding end being suitably applied in applications with a small number
portion of one of adjacent secondary coils 2A opposes the of turns of the primary coils and the secondary coils, in
winding start portion of the other of the adjacent secondary particular in high frequency inverters ( in the region of 50
coils 2A . kHz to 1 MHz).
[ 0213 ] The primary coil assembly 1 and the secondary coil 10221] In the high frequency transformer 100 the second
assembly 2 are combined together such that the primary ary coils 2A are moreover disposed at both ends, thereby
coils 1A are inserted between adjacent secondary coils 2A , making it easier to set a greater number of turns of the flat
and the winding start portions of the respective primary coils wire of the overall secondary coil assembly 2 than the
1A of the primary coil assembly 1 oppose the winding end number of turns of the flat wire of the overall primary coil
portion of one of adjacent secondary coils 2A of the sec assembly 1 than in a high frequency transformer configured
ondary coil assembly 2 , and the winding end portion of the with the primary coils 1A at both ends. The high frequency
primary coil 1A opposes the winding start portion of the transformer 100 is accordingly suitably employed in appli
other of the adjacent secondary coils 2A . All of the primary cations in which a high voltage high frequency current is
coils 1A and the secondary coils 2A are moreover arrayed so output.
as to be coaxial to each other.
[0214] In the primary coil assembly 1 , the winding start 11. Eleventh Exemplary Embodiment
portions and the winding end portions of the primary coils
1A configure crossing wires 1B that are pulled out to the [0222 ] Explanation follows regarding an example of a
outside . The crossing wires 1B are formed so as to straddle high frequency transformer of the present invention wherein
the outside of the adjacent secondary coils 2A , and the the high frequency transformer is configured with the pri
primary coils 1A are connected in series together at the mary coils inserted between the secondary coils, the primary
crossing wires 1B to configure the primary coil assembly 1 . coil assembly is formed by connecting together plural of the
The method for in series connecting together the primary primary coils in parallel, and the secondary coil assembly is
coils 1A at the crossing wires 1B is similar to as described formed from a single flat wire .
above in the seventh exemplary embodiment. [0223] As illustrated in FIG . 48 to FIG . 51, a high fre
[ 0215 ] While, in the secondary coil assembly 2, the flat quency transformer 110 of the eleventh exemplary embodi
wire configuring the secondary coil assembly 2 configures ment is provided with a shell- type ferrite core 4 including a
crossing wires 2B that are pulled out to the outside of the single circular cylinder shaped central core 4A , and a
secondary coils 2A at portions between adjacent secondary primary coil assembly 1 and a secondary coil assembly 2
coils 2A . into which the central core 4A is inserted . The shell-type
US 2018/0137967 A1 May 17 , 2018
15
ferrite core 4 is configured similarly to as described above in coil assembly 2 and the winding end side crossing wire 2B
the second exemplary embodiment and the fifth exemplary of the secondary coil 2A positioned at a third tier of the
embodiment. secondary coil assembly 2 respectively configure lead wires
[0224 ] In the primary coil assembly 1, start end portions 2C .
and finish end portions of the flat wires that form the primary [0235 ] As illustrated in FIG . 57 , the primary coils 1A of
coils 1A configure crossing wires 1B that are pulled out to the primary coil assembly 1 are configured in series , and the
the outside of the primary coil assembly 1. The crossing secondary coils 2A of the secondary coil assembly 2 are
wires 1B are connected in parallel by crossing bars 1E . The configured in parallel.
primary coil assembly 1 is thus configured by connecting [0236 ] The primary coil assembly 1 and the secondary coil
together in parallel three primary coils 1A that are of three assembly 2 are combined together similarly to as described
turns each . above in the tenth exemplary embodiment.
[0225 ] The winding start side crossing wire 1B of the [0237 ] The high frequency transformer 120 has a coupling
primary coil 1A positioned at a first tier of the primary coil rate of close to 100 % due to configuring the primary coils 1
assembly 1 and the winding end side crossing wire 1B of the at both ends, similarly to in the high frequency transformers
primary coil 1A positioned at a third tier of the primary coil of the first exemplary embodiment and the second exem
assembly 1 respectively configure lead wires 1? . plary embodiment.
[ 0226 ] The secondary coil assembly 2 is configured simi [0238 ] Due to employing the shell- type ferrite core 4 as
larly to as described above in the tenth exemplary embodi the core , similarly to the high frequency transformer of the
ment. second exemplary embodiment , the ratio of the core with
[ 0227 ] As illustrated in FIG . 52 , the primary coils 1A of respect to the coils is increased , thereby strengthening the
the primary coil assembly 1 are configured in parallel, and iron machine characteristics . The high frequency trans
the secondary coils 2A of the secondary coil assembly 2 are former 120 is accordingly suitably employed in applications
configured in series. with a small number of turns of the primary coils and the
[0228 ] The primary coil assembly 1 and the secondary coil secondary coils, in particular in high frequency inverters (in
assembly 2 are combined together similarly to as described the region of 50 kHz to 1 MHz ).
above in the tenth exemplary embodiment. [0239 ] Moreover, due to forming the primary coil assem
[ 0229 ] In the high frequency transformer 110 it is easier to bly 1 from a single continuous flat wire wound at a specific
set a greater number of turns of the flat wire of the overall interval, the effort of manufacturing the primary coil assem
secondary coil assembly 2 than the number of turns of the bly 1 by connecting separately formed primary coils 1A is
flat wire of the overall primary coil assembly 1 than in a high not required , such that the primary coil assembly 1 is easily
frequency transformer configured with the primary coils 1A manufactured . Moreover, since the secondary coils 2A of the
at both ends. Since the primary coils 1A are connected secondary coil assembly 2 are connected together in parallel,
together in parallel, the high frequency transformer 110 is the high frequency transformer 120 is suitably employed in
accordingly suitably employed in applications in which a applications in which a large current is output.
high frequency current of a large current is input and a high
voltage high frequency current is output. EXPLANATION OF THE REFERENCE
NUMERALS
12 . Twelfth Exemplary Embodiment [0240 ] 1 primary coil assembly
[0230] Explanation follows regarding an example of a 10241 ] 1A primary coils
high frequency transformer of the present invention wherein 10242 ] 1B crossing wires
the secondary coils are inserted between the primary coils , 10243] 1C lead wires
the primary coil assembly is formed from a single flat wire, [0244 ] 1D crossing wire
and the secondary coil assembly is formed by connecting [0245 ] 1E crossing bars
together plural secondary coils in parallel. [0246 ] 2 secondary coil assembly
[0231] As illustrated in FIG . 53 to FIG . 56 , a high fre 0247 ] 2A secondary coils
quency transformer 120 of the twelfth exemplary embodi 10248 ] 2B crossing wires
ment is provided with a shell- type ferrite core 4 including a [0249 ] 2C lead wires
single circular cylinder shaped central core 4A , and a [0250 ) 2D crossing wire
primary coil assembly 1 and a secondary coil assembly 2 [0251] 2E crossing bars
into which the central core 4A is inserted . The shell-type 10252 ] 3 core- type ferrite core
ferrite core 4 is configured similarly to as described above in [0253 ] 3A core
the second exemplary embodiment and the fifth exemplary [0254 ] 4 shell- type ferrite core
embodiment. [ 0255 ) 4A central core
[ 0232] The primary coil assembly 1 is configured similarly [0256 ] 5 three - legged ferrite core
to as described above in the first exemplary embodiment. 102571 5A columnar cores
[0233 ] In the secondary coil assembly 2, start end portions [0258 ] 5B top plate
and finish end portions of the flat wires that configure the [0259] 5C bottom plate
secondary coils 2A configure crossing wires 2B that are [0260] 7 insulating member
pulled out to the outside . The crossing wires 2B are con [0261] 7A insulation tabs
nected in parallel by crossing bars 2E . The secondary coil (0262 ) 7B insulation tab retaining members
assembly 2 is thus configured by connecting together in [ 0263] 10 high - frequency transformer
parallel three secondary coils 2A that are of three turns each . [0264 ] 11 primary coil assembly
[ 0234 ] The winding start side crossing wire 2B of the [0265 ] 12 primary coil assembly
secondary coil 2A positioned at a first tier of the secondary [0266 ] 13 primary coil assembly
US 2018/0137967 A1 May 17 , 2018
16

[0267 ] 20 high frequency transformer each other, and one individual of the primary coils is
[0268 ] 21 secondary coil assembly disposed inside each of the respective intervals such
[0269 ] 22 secondary coil assembly that a winding start portion of each of the primary coils
10270 ] 23 secondary coil assembly opposes a winding end portion of the one secondary
[0271 ] 30 three phase high frequency transformer coil, and a winding end portion of the primary coil
[0272 ] 40 high frequency transformer opposes a winding start portion of the other secondary
[0273 ] 50 high frequency transformer coil, and
[0274 ] 60 three phase high frequency transformer a primary coil assembly is configured by connecting the
[0275 ) 70 high frequency transformer primary coils in series or in parallel at the outside of the
(0276 ] 80 high frequency transformer secondary coils so as to connect across the secondary
[0277 ] 90 high frequency transformer coils, and a secondary coil assembly is configured by
[0278 ] 100 high frequency transformer connecting the secondary coils in series or in parallel at
10279 ] 110 high frequency transformer the outside of the primary coils so as to connect across
[0280 ] 120 high frequency transformer the primary coils.
1 . ( canceled ) 6 . The high frequency transformer of claim 3 ,wherein the
2 . A high frequency transformer comprising : number of the primary coils is four or more , and the number
a first coil assembly including a plurality of first coils that of the secondary coils is three or more.
are respectively configured by winding a flat wire 7 . The high frequency transformer of claim 5 , wherein the
edgewise a plurality of times , with the first coils number of the secondary coils is four or more , and the
disposed at specific intervals such that a winding end number of the primary coils is three or more .
portion of one of adjacent first coils opposes a winding 8 . The high frequency transformer of claim 2 , wherein an
start portion of the other of the adjacent first coils; and insulating member is inserted between the primary coils and
a second coil assembly including a plurality of second the secondary coils .
coils that are respectively configured by winding a flat 9 . The high frequency transformer of claim 2 , wherein the
wire edgewise a plurality of times, with the second flat wire configuring the primary coil assembly and the flat
coils disposed at specific intervals such that a winding wire configuring the secondary coil assembly differ from
end portion of one of adjacent second coils opposes a each other in width , in thickness, or in both width and
winding start portion of the other of the adjacent second thickness.
coils ; wherein 10 . The high frequency transformer of claim 2, wherein a
one of the first coil assembly and the second coil assembly ferrite core is inserted through the primary coil assembly and
is formed from a single flat wire, the secondary coil assembly .
the other of the first coil assembly and the second coil 11. The high frequency transformer of claim 10 , wherein
assembly is formed by connecting together in series or the ferrite core is a shell-type core .
in parallel a plurality of coils that are respectively 12 . The high frequency transformer of claim 10 , wherein
configured by winding a flat wire edgewise a plurality the ferrite core is a core -type core.
of times, 13 . The high frequency transformer of claim 12 , wherein
the first coil assembly and the second coil assembly are primary coil assemblies that are respectively mounted on a
disposed such that pair of central cores of the core - type core and secondary coil
the second coils are inserted between adjacent of the assemblies that are respectively mounted on the pair of
first coils such that a winding start portion of each of central cores are respectively connected in series.
the second coils in the second coil assembly opposes 14 . The high frequency transformer of claim 12 , wherein
a winding end portion of one of adjacent first coils in at least one of primary coil assemblies respectively mounted
the first coil assembly, and a winding end portion of on a pair of central cores of the core -type core or secondary
each of the second coils opposes a winding start coil assemblies respectively mounted on the pair of central
portion of the other of the adjacent first coils . cores are connected in parallel.
3 . The high frequency transformer of claim 2 , wherein : 15 . The high frequency transformer of claim 2 , further
the first coils are primary coils and the second coils are comprising :
secondary coils , and the first coil assembly is a primary three each of the primary coil assemblies and the second
coil assembly and the second coil assembly is a sec ary coil assemblies ;
ondary coil assembly . three columnar cores that are formed from ferrite and are
4 . The high frequency transformer of claim 2 , wherein : disposed at even intervals around the circumference of
the first coils are secondary coils and the second coils are a circle ;
primary coils, and the first coil assembly is a secondary a top plate that is formed from ferrite and is coupled to one
coil assembly and the second coil assembly is a primary end of each of the columnar cores; and
coil assembly . a bottom plate that is formed from ferrite and is coupled
5 . A high frequency transformer comprising: to the other end of each of the columnar cores ; wherein
a plurality of primary coils formed by winding a flat wire the three columnar cores are respectively inserted into
edgewise a plurality of times , and a plurality of sec
ondary coils formed by winding a flat wire edgewise a each of the primary coil assemblies and each of the
secondary coil assemblies , and
plurality of times; wherein the primary coil assemblies and the secondary coil assem
the secondary coils are disposed at mutual intervals such blies are respectively configured with a Y connection ,
that a winding end portion of one of the secondary coils
and a winding start portion of another of the secondary or with a delta connection .
coils that is adjacent to the one secondary coil oppose * * * * *